Graphic image fusion

ABSTRACT

An in-mold and in-line decorating method is disclosed which, using a single sheet layer, allows the placement of the highest possible quality graphics into the surface of products made from a variety of moldable thermoplastic, thermoset, and vulcanizable materials using a variety of molding processes. The methods also provide new or improved capabilities for product identification, safety, and serialized tracking.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The application claims the benefit of U.S. provisionalapplication Serial No. 60/125,316 filed Mar. 19, 1999.

BACKGROUND OF THE INVENTION

[0002] The present invention is directed to creating in-mold and in-linedecorated articles having higher quality than previously attainable,greater permanence than previously available, using molding techniquespreviously excluded, using processes and materials previously excluded,and offering improvements in yield, throughput and scrap rates. Thepresent invention provides images of near photographic quality that arehighly resistant to fading, chemicals and abrasion that can be producedusing both thermoplastic and thermosetting processes. The presentinvention makes possible new in mold and in-line capabilities andprovides new or improved opportunities for product decoration and forproduct labeling where permanence, long life, safety labeling, productidentification, ownership or serialization labels, or production lotidentification is needed.

[0003] Product manufacturers place a high value on the ability todeliver a product with a high quality graphic surface. This hastraditionally required a trade-off between the quality of the image andthe permanence of the image and its print media. The highest qualityachievable has been to lithographically print adhesive labels, which areapplied after aforesaid articles have been molded. These suffer frompoor adhesion to many types of materials resulting in decorative labelsthat peel and degrade the appearance of the product. Loss of adhesion isexacerbated by environmental factors such as moisture and large changesin temperature and is particularly acute in outdoor applications. Theloss of labels containing safety related information is obviously a muchmore serious issue. Labels on products used by small children alsopresent a choke hazard should the labels come off. In many casesinformation is placed onto the article using other post-moldingdecorating techniques such as heat transfer and pad and screen printing.These techniques result in the lowest quality image and are generallylimited to one or two colors in relatively non-complex designs. In manycases, an image such as a logo or lettering is actually a part of themold creating a raised area that receives the transferred color. Both ofthese techniques also add complexity to the manufacturing process byadding a post-molding step wherein the article is given its graphicimage. Not only do these techniques add cost and manufacturing cycletime, but aforesaid techniques also introduce opportunities to convert apart into a quality reject if the image application is not doneperfectly. Neither adhesive labels nor post mold decorating techniquesinvolving transfer of image or color can effectively decorate overcompound curvature areas or the sides of raised areas. Current art isessentially limited to flat or single curvature surfaces.

[0004] The shortfalls inherent in aforesaid post molding decoratingtechniques have resulted in the development of in-mold decoratingtechniques. In-mold decorating is characterized by the preparation ofgraphics, normally using screen-printing techniques on a polymer filmmaterial of composition compatible with the polymer to be used inmolding the part. The film traditionally used for said in molddecorating is clear allowing the underlying molded polymer to showthrough. Many techniques use complex multi-layered films in an attemptto achieve a satisfactory in-moldable product. The printed film isnormally placed into the mold so that the molten polymer flows over theink, which is trapped between said film and said polymer. Temperaturesand pressures characteristic of said technique drives requirements forscreen printing inks that can withstand said process. The graphic detailquality achievable by said techniques is limited by the environment inwhich said inks must remain stable and not wash out or flow with themolten polymer. The cost of screen printing, with the requirement toseparately deposit each color, results in total costs that diminish thecompetitiveness of in-mold decorated products made using said technique.

[0005] There is a plurality of reasons why yields of good parts arelower than desired by manufacturers when using said in-mold decorating.Causative factors include damage to the graphic image on the surface ofthe sheet during placement or molding, damage to the sheet itself duringmolding and lack of stability of the printed sheet in the mold duringmolding. Said graphic image damage results primarily from the robustnessof the inks and lack of protection of same from the temperatures andpressures common in said molding processes. Said sheet damage resultsprimarily from stretching or penetration of said sheet during moldingdue to the pressures of molding and the flow of molten materials overthe sheets to their edges. Said lack of stability involves the movementof said printed sheet within the mold due primarily to the flow ofmolten material over said sheet causing said sheet to slide with respectto the mold surface or to lift from said mold surface. Said slidingresults from insufficient coefficient of friction between said sheet andsaid mold surface. Said lifting results from said sheet presenting toomuch cross section to the flowing molten material, particularly when theentry of said molten material is not within the boundaries of saidgraphic sheet and said molten material must impinge upon the verticaledge of said printed sheet. Said lifting problem is exacerbated bythicker printed sheets, which may be used to provide the needed tensileproperties. Common techniques used to enhance said stability includeinducing electrostatic charges between said sheet and said mold surfaceto prevent movement during molding, texturing said mold surface toincrease friction between said sheet and said mold surface, and use ofdetents or pockets in the mold to constrain said printed sheet. Problemsinherent in using said electrostatic charge techniques include theinability to maintain said charge at a high enough level and for a longenough period to properly complete the molding process. The dissipationof said charge is accelerated by the typical marginal dielectriccharacteristics of said printed sheet. Said surface texturing and use ofdetents or pockets are currently the best available options either usedin lieu of or in concert with said electrostatic charging.

[0006] Some of the shortcomings of both post molding decorating andtraditional in-mold decorating have been partially overcome in the areaof thermoplastic compression molded products where a printed sheet hasmolten polymeric material fused to its non graphic surface. Compressionmolding using a billet approach falls into the category of a low stresstechnique thereby overcoming the problems inherent in highly tortuoustechniques such as injection molding. U.S. Pat. No. 4,861,644 disclosedthe printing using various techniques, including offset lithography, ofmicroporous substrates. U.S. Pat. No. 4,892,779 discloses the fusion ofa printed microporous sheet to other materials using a variety ofmolding techniques. Disclosed, but not claimed is injection and blowmolding of polyolefins. U.S. Pat. Nos. 5,591,384, 5,626,339, 5,637,329,and 5,800,757 all disclose the manufacture of thermoplastic productswith graphics molded into the surface of the product during manufactureusing low stress molding techniques such as compression and structuralfoam molding. These patents cite the use of polymers which arecompatible with the polymer used to make the sheet which is in-molded tosaid polymer. While U.S. Pat. No. 5,512,227 discloses use of polyolefinfilms and U.S. Pat. Nos. 4,418,033, 4,650,533, 5,227,222, 5,338,396,5,514,427, 5,536,539, 5,698,283, 5,705,255, 5,707,472, and 5,795,527disclose use of non-polyolefin films in injection molding applications,they demand a multi-layer “sandwich,” some involving adhesives to be aneffective method of in-molding graphics during injection molding.Several of these techniques also require post-molding stripping ofcarrier sheets or layers from the finished part. Other patents, such asU.S. Pat. No. 5,676,981, require specialized techniques such as heatingthe graphic sheet to assure good adhesion and stability during theinjection molding process. Other techniques such as described in U.S.Pat. Nos. 4,418,033 and 4,369,157 require a continuous strip of in-molddecorating material to be repeatedly advanced between each mold closure;this routinely introduces errors in alignment of the image to the partresulting in a quality reject. Still other techniques such as disclosedin U.S. Pat. Nos. 4,330,578 and 5,629,029 require specialized molds ordouble injection steps to accomplish the in-mold decorating operation.Still other techniques for blow molding such as disclosed in U.S. Pat.Nos. 4,808,366 and 4,983,348 do not result in actual permanent fusionattachment of the graphic image sheet to the finished part. Still othertechniques such as disclosed in U.S. Pat. No. 4,427,615 require pins inthe mold upon which to hang the printed sheet to be in-molded.

[0007] In summary, existing methods of achieving said in-molded graphicsgenerally depend on the similarity of materials between the graphicallyprinted film and the substrate material to which the graphic is molded.Said methods address only thermoplastic applications. Where the use ofdissimilar materials is disclosed there are complex techniques, such asmulti-layering, required to affect the molding. The current state of theart offers no techniques for in-mold decorating with lithographicallyprinted images using high stress manufacturing techniques such asinjection molding. Since the majority of current molding is injection,there is a need for a method of economically achieving high yield, highthroughput in-mold decorating manufacture of high quality graphicproducts. The current state of the art offers no techniques forintroduction of a three dimensional graphic into the cavity of a mold toproduce a dimensional part decorated in the mold with graphics on alltop and side surfaces. Since most polymeric materials undergo shrinkageduring post-molding cooling, there are issues with in-mold decoratingtechniques not matching the shrink rate; the current state of the artdoes not offer techniques for in-mold decorating where the image willautomatically exhibit the same shrink rate as the polymer into which itis molded.

SUMMARY OF THE INVENTION

[0008] In order to overcome the deficiencies in prior art it isnecessary that a method be developed to provide a system solution. Thesystem solution of the present invention provides a printable sheet ofnot greater than ten mil thickness that can survive the tortuousinjection molding environment and which is in-moldable with a widevariety of thermoplastic and thermoset materials; a family of inks thatproduce the highest quality images and can survive the molding processwhile also exhibiting excellent flexibility and resistance to fading inUV light; a family of coatings that aid the molding process and provideadded permanence to the printed image in abrasive, chemical, or UV lightexposure environments; a printed and coated sheet that can, if needed,be thermoformed to fit a complex mold face geometry; techniques forefficiently and positively placing and holding the printed sheet in themold; high stability of the printed sheet in the mold during molding;and which is effective in a wide variety of molding techniques.

[0009] The system of the present invention exhibits the ability to placethe aforesaid mentioned single layer printed and coated sheet into moldsheretofore used for undecorated product manufacture and to produce anin-mold decorated product.

[0010] With respect to said printable sheet, there is a plurality ofprecipitated silica filled microporous sheet materials commerciallyavailable in the marketplace. Such materials exhibit varying degrees ofrobustness in the tortuous injection-molding environment. Material soldby PPG Industries, Pittsburgh, Pa. under the trade name MiST™ is, whenproperly coated as explained herein, found to be satisfactory for themost demanding molding environments including thermoset applicationswhere the material will be exposed to high temperatures for extendedtime periods for curing. Other materials, such as Daramic™ manufacturedby Daramic, Inc. of Owensboro, Ky. are generally satisfactory forthermoplastic injection molding applications if treated using coatingsto improve their tensile properties and stability in the mold. Use ofsurface treatment coatings make ten mil thickness material suitable inall applications and makes seven mil thickness material suitable in manyapplications.

[0011] With respect to said inks, there are families of satisfactorylithographic, gravure, flexographic, and screen inks available in themarketplace from a number of sources by referring to inks suitable foruse with PPG Industries Teslin® printable sheet. The use of such inks isan essential element in obtaining a quality print on silica-filledmicroporous sheet materials. Reference is made to the Grafusion™ seriesof lithographic inks and the GRA series of screen inks which have beenoptimized for the aforementioned silica filled micro-porous materialsand which demonstrate the flexibility and robustness to provide andmaintain a high quality image through a tortuous injection moldingprocess. Both of these series of inks exhibit exceptional faderesistance in prolonged UV exposure. These inks are available fromPinnacle Products Group, Ltd. of Dayton, Ohio. Such inks comprise apigment and carrier which are formulated to withstand temperatures of upto 600° F.

[0012] With respect to said coatings, there are families of UV energycross-linkable coatings that provide the said printed silica-filledmicroporous materials with the performance enhancements essential forsuccessful high yield molding of articles. By the nature of theirmolecular level changes during curing such coatings enhance the tensileproperties of the printed sheets reducing the tendency of the sheet tostretch as molten material flows over the sheet to its edges. Increasingthe tensile properties also allows the use of thinner material such asseven mil thickness; this is important because it reduces the crosssection presented at the sheet edge where an excessive thickness inducesdisruption of the material flow causing said sheet to lift from the moldsurface. The increases in tensile properties are also of value inminimizing stretch thus making the printed sheets usable in a continuousroll fed sheet extrusion process where graphics are fused to extrudateas it is produced. By the nature of the molecular changes that occurduring curing the coatings also protect the ink during the moldingprocess and provide said printed sheets with an increased surfacecoefficient of friction which significantly enhances the stability ofthe printed sheet within the mold during tortuous molding processes.Such sheet stability lowers the potential movement or float of theprinted sheet as molten material flows over the sheet to its edges; thestability is essential to achieving high yield during tortuous moldingprocesses. The increased coefficient of friction is also an essentialperformance factor if the printed articles are to be used in underfootapplications where slip resistance is an important safety issue. Whenneeded such coatings can be formulated, and are commercially availablewhich also enhance the resistance of the printed sheets from degradationby chemicals such as petroleum distillates and solvents which couldcontact the surface of the product in many applications. When neededsuch coatings can also be formulated and are commercially available toenhance the resistance of any of the products to color fading fromprotracted exposure to UV light in outdoor or other high sunlightexposure applications. Such coatings also provide suitable dielectricperformance so that printed and coated sheets can be held in the moldcavities using electrostatic means without the degradation ordissipation of the electrostatic charge prior to mold closure andcompletion of the molding process. Satisfactory, but not optimum, UVcurable coatings are available from a number of sources by specifying aclear coat that will adhere to lithographic printed images and whichexhibits whatever performance factors such as those cited above areneeded for the specific application. A suitable series of such coatingshas been optimized to enhance the most important properties for themajority of product applications is the GRA series of coatings, whichare clear variants of the screen inks previously cited. These coatingsare available from Pinnacle Products Group, Ltd. of Dayton Ohio. Suchcoatings are UV crosslinkable coatings containing an acrylate ester.

[0013] The invention makes possible many new capabilities and opens manynew opportunities in the field of in-mold decorating. First, theinvention allows improving the quality of images that can be in-moldedby implementing offset lithography, flexographic and gravure printing asoptions. Second, the invention provides in-molding approaches that areeasier to implement and have lower production costs by enhancing theeffectiveness of electrostatic adhesion and often allowing in-moldingwithout modifying molds. Third, the invention provides products andimages which are more robust and durable, particularly in the areas ofUV induced fading, abrasion, and slip resistance in underfootapplications. Fourth, the invention provides methods that lower thescrap rates from unsuccessful attempts by improving the stability of thein-mold graphic element during molding and by positive fusion of thegraphic element into the surface of the molded part. Fifth, theinvention provides for implementation with minimum impact on productionprocess cycle times, including the implementation of robotic handling,hence making in-mold decorating more cost competitive. Sixth, theinvention provides the ability to implement in-mold decoration inthermosetting and vulcanization applications opening a plurality of newproducts to such decoration. Seventh, the invention provides forimplementing in-mold and inline decorating in a wider range of moldingtechniques including extrusion and thermoforming while simplifyinginjection molding and blow molding. Eighth, the invention provides aplurality of new options for decorated molded products through suchapplications as the manufacture of polyolefin products that can bescreen printed without using specialized inks or corona treatments, theability to attach metallized foils to molded parts, and the ability toattach pressure sensitive adhesive materials such as reflective tape tomaterials to which they would not otherwise adhere. Ninth, the inventionprovides new or improved opportunities for permanent product labeling inthermoplastic, thermosetting, and vulcanizable product applicationsallowing in-molding of safety labels, product identification labels,product serialization labels, product ownership labels for securitypurposes, part number labels, life cycle tracking labels, and productionlot identification labels containing text, logos, graphics or barcodes.Tenth, the invention provides for identifying that said products havebeen altered or misused, thus providing an added security feature to thefinished molded product. Eleventh, the invention allows for the in-molddecoration of deep dimensional and three dimensional molded parts.Twelfth, the invention eliminates concerns over the differences inpolymer shrink rates between an in-moldable label and the polymer towhich it is molded. Lastly, the invention allows manufacturers of anin-mold decorated product to have the image assume the texture of theunderlying molded material as imparted by the mold surface due to theinherent flexibility of the sheet materials used.

[0014] Accordingly, it is an object of the present invention to providemethods for in-mold decorating which provides high quality images ontoextruded and molded parts, and to provide products produced by thosemethods. These, and other features and advantages, will become apparentfrom the following detailed description and the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention is illustrated by the followingrepresentative, but non-limiting, examples.

EXAMPLE 1

[0016] A sheet of PPG Industries MIST® ten mil thick material is printedusing offset lithography with a four color process image using inks fromthe Grafusion™ series available from Pinnacle Products Group, Ltd.,Dayton, Ohio. The printed image is then coated via screen printing usingGRA-C501 coating also available from Pinnacle Products and is fed intothe lower gap of a sheet extrusion line roll stack with its printedsurface against the lower roller containing a leatherette texture andits reverse side coming in contact with a thermoplastic rubber materialderived primarily from recycled truck tires. This continuously operatingin-line process produces a rubber mat with a high quality image fusedinto its surface. The graphic image has the leatherette texture, theprinted and coated film having conformed to said leatherette texture.The graphic image displays no fading in outdoor exposure to sunlightafter six months. The coating prevents serious degradation to thegraphic image from scuffing abrasion from foot traffic. Laboratorymeasurements of the coefficient of friction using ASTM D-2047 disclosesa value of 0.80, well above the threshold of 0.50 to qualify as slipresistant in underfoot applications. The mat is usable as an underfootadvertising product in outdoor and underfoot applications. The graphiccompletely covers the unattractive surface of the recycled contentmaterial thereby presenting an aesthetically pleasing product.

EXAMPLE 2

[0017] A sheet of PPG Industries MiST® seven mil thick material isprinted with a using offset lithography four color process image usinginks from the Grafusion™ series. The printed image is then coated viascreen printing using GRA-C501 coating and is then die cut to the shapeof a control panel label. The die cut piece is then positioned in thecavity of an injection mold and is electrostatically treated using aTantec High Voltage Electrostatic Charging Device. The mold is thenclosed and the control panel part is injection molded usingpolypropylene. When the mold opens a control panel part containing saidgraphic fused into the appropriate part of its surface is ejected. Thisexample demonstrates the capability of the invention to replace postmolding decorating where prior state of the art in-mold decoratingtechniques were unable to provide a satisfactory solution. The resultingpart is suitable for use by the customer in lieu of a part wherepreviously an adhesive label had been applied in a post moldingoperation.

EXAMPLE 3

[0018] A sheet of PPG Industries MiST® ten mil thick material is printedwith text, a logo, and a unique serialized barcode using a hightemperature carbon ink ribbon in an Intermec 4440 printer. The sheet isthen scored with an intersecting cross hatch. The printed and scoredsheet is then given a silicone coating on the printed side. The rearside of the printed sheet is coated with unvulcanized rubber and saidsheet is placed on the sidewall of an unvulcanized tire. The tire thenundergoes vulcanization producing a finished tire containing a permanentlabel providing tire ownership information and serialization fortracking the tire during the remaining manufacturing steps and as partof a tire inventory throughout its useful life. The tire with labelattached undergoes temperature and flexure testing to simulate on theroad conditions and the label remains intact. The label is cleaned usinggasoline and typical solvents such as toluene, heptane, andmethyl-ethyl-ketone and it shows no degradation of the image with thebarcode remaining readable using automatic barcode reading equipment.This example demonstrates the capability of the invention to place apermanent and durable in-mold decoration onto a part in a thermosettingprocess. The product provides the tire owner with increased securityagainst theft of his tires and a method of tracking the use andrecapping of the tire throughout its useful life. The cross hatchcutting has resulted in a label that flexes, but does not permanentlydeform in extreme flexure, with the tire while in use

EXAMPLE 4

[0019] A sheet of PPG Industries MIST® seven mil thick material isgravure with a wood grain pattern and coated with GRA-C501 coating. Apiece of this sheet is placed onto the core surface of an unmodifiedmold designed to make a refrigerator ice tray and is treatedelectrostatically to hold it in place. The mold is closed and a part isinjection molded using ABS plastic. The molding process produces an ABSice tray with a wood grain finish using a polyolefin printed sheet. Thetest demonstrates the capability of the invention in molding ofdissimilar materials and the ability to hold an in-mold graphic sheet onthe core of an injection mold where it is subjected to the most tortuousforces. The finished part offers the customer the capability to place apermanent instruction label on the part in production.

EXAMPLE 5

[0020] A sheet of seven mil thick PPG Industries MIST® material isprinted with a four color process lithographic image using inks from theGrafusion™ series. The printed image is then coated using GRA-003coating available from Pinnacle Products Group, Ltd., Dayton, Ohio. Thesheet is then placed on the vertical cavity wall of a 30 gallon refusecontainer mold and held in place using electrostatic treatment. The moldis then closed and a twenty pound part is injection molded usingpolyolefins. The molding produces a refuse container containing a highquality durable and abrasion image molded on its side. The processdemonstrates the stability of the in mold graphic on a smooth surfacewithin the mold where a high volume of high pressure molten materialmust flow past the graphic to fill the mold. The process furtherdemonstrates the effectiveness of the invention in performing in-moldgraphic decoration without changes to the mold or molding equipment. Theprocess provides the customer with a method of customizing suchcontainers for individual communities.

EXAMPLE 6

[0021] A sheet of ten mil thick Daramic™ material available fromDaramic, Inc., Owensboro, Ky. is printed lithographically with a fourcolor process image using inks from the Grafusion™ series. The printedimage is then coated first with GRA-C501 and then with GRA-003 coatingsand is fed into the lower gap of a sheet extrusion line roll stack withits printed surface against the lower roller containing a leatherettetexture and its reverse side coming in contact with a proprietarythermoplastic rubber material derived primarily from recycled trucktires. This continuously operating in-line process produces a rubber matwith a high quality image fused into its surface and a v-grooved backwhich is cut to the appropriate size for use as a truck mud flap. Theproduct is then installed on a truck for in service testing where themud flap and its image display satisfactory abrasion and fade resistancein a high stress environment for six months. The mud flap productprovides the capability to carry a photographic quality image on a mudflap for advertising purposes.

EXAMPLE 7

[0022] A sheet of ten mil MiST™ material has an aluminum metallizedmaterial available from Kurz-Hastings Corporation deposited thereuponusing heat lamination creating an in-moldable sheet of MiST™ with analuminum metallized surface. The sheet of metallized surface MiST™ isthen placed into the cavity of an injection mold opposite the injectiongate and a part is molded using polycarbonate. The resulting part isproduced having a metallized and acceptably reflective permanent surfacefor use in the headlight assembly of a lawn tractor. The sheet of MiST™material creates a vehicle for permanent attachment of the metallizedsurface to a product where said metallized surface could not otherwisebe permanently attached.

EXAMPLE 8

[0023] A sheet of ten mil MiST™ material is printed with a set of tenprocess color images using a Xerox Docutech® color laser printer and isthen coated with GRA-C501. The images are then die cut from the sheetand are placed one at a time in an injection mold and a part is moldedusing ABS plastic. The parts that are produced contain a permanentin-molded full color image and are usable for placement on otherproducts as a manufacturer identifying plaquard.

EXAMPLE 9

[0024] A sheet of ten mil Daramic™ material is printed via offsetlithography four color process using Grafusion series inks and is thenscreen coated using GRA-C501 coating. The sheet is then fused into thesurface of rubber derived from recycled tires via a sheet extrusionprocess. The resulting graphic product then has adhesive reflective tapepressed onto its surface producing a graphic product with a reflectiveborder where said reflective tape will not adhere to said rubber of saidproduct produced without said graphic molded into its surface.

EXAMPLE 10

[0025] A sheet of ten mil Daramic™ material is printed via offsetlithography using Grafusion series inks and is then screen coated usingGRA-C501 coating. The sheet is then placed in the cavity of a molddesigned for blow molding a water bottle and is momentarily exposed toelectrostatic energy. The mold is then closed and a bottle is blowmolded using polyethylene. When the mold is opened a bottle with apermanent image fused into its surface is removed.

EXAMPLE 11

[0026] A sheet of PPG Industries MiST® ten mil thick material is printedwith text, a logo, and a unique serialized barcode using a hightemperature carbon ink ribbon in an Intermec 4440 printer and is thencoated using GRA-C501 coating. The printed and coated sheet is thenplaced in a thermoforming mold with a sheet of polyethylene and a partis molded using vacuum forming. When the mold is opened the part has apermanent barcode label fused into its surface.

EXAMPLE 12

[0027] A sheet of ten mil MiST™ material has a metallized materialcommercially available from API Foils, Inc. deposited thereupon creatingan in-moldable sheet of MiST™ with a metallized surface. Said sheet ofmetallized surface MiST™ is die cut to an appropriate size and scored sothat it will fold over the 0.25 inch thick edges of a part 2.5 inches by4.5 inches. The die cut sheet is then placed into the cavity of aninjection mold and a part is molded using polycarbonate. The resultingpart is produced having a permanent metallic appearing surface for useas the cover plate for an electrical wall switch but without the safetyneed to assure electrical grounding of said cover plate. The sheet ofcoated MiST™ material creates a part that appears to be metal but whichis non-conductive electrically.

EXAMPLE 13

[0028] A sheet of seven mil MiST™ material has a gold, red and chromemetallized material commercially available from Kurz-HastingsCorporation deposited thereupon in the form of a logo creating anin-moldable sheet of MiST™ carrying a metallized logo on its surface.The sheet of metallized surface MiST™ is coated using GRA-C501 coatingand is then placed into the cavity of an injection mold and a part ismolded using thermoplastic rubber. When the mold is opened an automotiveairbag cover containing a metallized color logo is permanently fusedinto the surface and the airbag cover is ready for installation in anautomobile for which the logo is appropriate.

EXAMPLE 14

[0029] Multiple sheets of ten mil MIST© material are lithographicallyprinted using Grafusion™ series inks with a NASCAR© image using and arethen coated with GRA-C502 coating using a Steinemann Roll Coatingmachine. The printed and coated image are then die cut to a shape thatcan be folded into a three dimensional representation of the specificrace car design. Some of the cut pieces are folded over a fixture withoverlapping edges and held in place while a hot tip controlled at 400degrees F. is run across the joints. The overlapping edges weld togetherproducing a permanently formed three-dimensional representation of theracecar. Other sheets are folded into the desired three dimensionalshape and tack welded using a Branson Model 420 Ultrasonic Welder. Bothtypes of welded image sheets are then placed into the cavity of a moldin the shape of a racecar. The mold is closed and polypropylene at 380degrees F. is injected into the mold producing parts in the shape of aracecar with identifying graphics molded into their surfaces. The inmold decorated parts are then used as lids for beverage coolers.

EXAMPLE 15

[0030] A roll of ten mil Daramic™ material, ten inches wide is printedvia four color process flexography and is then screen coated usingGRA-C501 coating at the end of the flexographic process. The roll isthen separated into individual images that are placed in the cavity of amold designed for injection molding a carrying case and is momentarilyexposed to electrostatic energy. The mold is then closed and a case ismolded using polypropylene. When the mold is opened a case with apermanent image fused into its surface is removed.

EXAMPLE 16

[0031] A sheet of ten mil Daramic™ material is printed via offsetlithography using Grafusion inks and is then screen coated usingGRA-C501 coating. The sheet is then placed in the cavity of a molddesigned for injection molding the cover for a vacuum cleaner; the sheetis placed over an area in the mold intended to produce a raised logo onthe molded part that would have post molding decoration using heattransfer of foil. The sheet is momentarily exposed to electrostaticenergy to hold it in position and the mold is then closed and a part ismolded using ABS plastic. When the mold is opened a part with apermanent image fused into its surface is removed; the in-molded graphicimage has conformed to and completely covered the top and sides of theraised logo area. A post molding decorating process, heat transfer ofmetallic foil, is performed placing the foil decoration on top of thein-molded graphic in the raised logo areas.

EXAMPLE 17

[0032] A sheet of ten mil Daramic™ material is printed via offsetlithography using Grafusion yellow and black inks creating a sheet ofcaution labels of a type mandated by law for attachment to the lids ofmunicipal waste containers. The printed sheet is then screen coatedusing GRA-C501 coating. The sheet is then placed die cut producingindividual labels which are then placed in a cassette holder sized forthe labels by Geiger Robotic Handling Company. A robotic arm withappropriate end of arm tool made by Geiger then removes one label fromthe cassette using suction and transfers it the mold cavity of aninjection mold designed to mold a trash container lid. The end of armholds the label in position while an electrostatic wand element of theend of arm tool applies electrostatic energy to pin the graphic againstthe mold surface. The robot then withdraws, the mold closes, andpolyethylene is injected into the cavity of a mold. When the mold opensa lid containing the mandated permanent labels is ejected.

EXAMPLE 18

[0033] A sheet of then mil MIST® material is printed using four colorprocess offset lithography with a set of advertising images and thenprinted on the reverse side of each image with a logo, text and atelephone number using 50% density cyan color ink. The four colorprocess printed surface is screen coated with GRA-C501 coating material.The sheet is then die cut into individual labels having a four colorimage coated side and a single color uncoated side. A label is placedinto a mold designed to produce the lid for a storage box with the fourcolor side against the mold face and is pinned in position usingelectrostatic energy. The mold is then closed and crystal styrene isinjected against the one color printed side of the label. When the moldopens the process has produced a transparent lid with a four color labelon showing on its top and a one color image showing and readable throughthe transparent lid material when the box is opened.

EXAMPLE 19

[0034] A sheet of unprinted 10 mil MIST® is fused to the surface of arubber sheet during extrusion. The sheet is then cut to a specifiedshape and placed in an injection mold with the rubber against the moldsurface and the MIST® side exposed to the injection of polypropylene.When the polypropylene is injected it fuses to the MIST® and creates apart that is part rubber and part plastic having a permanent bond,without adhesives, between two materials that would not normally bond toone another. The resulting product approximates a shoe sole.

EXAMPLE 20

[0035] One side of a sheet of 10 mil thick Daramic material is coatedusing heat lamination with an electrically conductive film. The sheet isthen fused to the surface of a rubber sheet during extrusion. The resultis a flexible product containing a surface that exhibits electricalconductivity and can serve as a circuit or anelectromagnetic/electrostatic shield.

EXAMPLE 21

[0036] A sheet of 10 mil thick MIST® is four color offset lithographicprinted with left and right view photographic mallard duck imagesproduced using distortion printing where the image is compressed indesignated areas. The sheet is then coated using screen printing withGRA-C501 coating. The printed and coated sheet is then vacuum formed tothe dimensions of a duck decoy causing the distortion printed areas toassume normal color and proportion. The vacuum formed printed sheet iscut into left and right view pieces which are then placed in theappropriate cavities of a blow mold and molded with polyethylene. Whenthe mold is opened two halves of a duck decoy having a photographicquality image are removed and mated to form a finished decoy. Theprocess replaces hand painting of each decoy with a lesser quality imageand demonstrates the ability to mold graphics to deeply dimensionalproducts providing higher quality at lower cost than the previousmethod.

EXAMPLE 22

[0037] A sheet of 10 mil thick MIST is printed using four color processoffset lithography with an image approximating the appearance ofstainless steel. The printed sheet is then coated using screen printingwith GRA-C501 coating and die cut to the desired shape. The cut sheet isthen placed in a mold and structural foam molded using Norell®polyphenol-oxide to produce a part usable as a bank safety deposit doorhaving the appearance of stainless steel. This demonstrates the abilityof the method to allow use of high performance polymers in applicationswhere the polymer provides the needed performance but the marketperception demands an appearance other than plastic.

[0038] The foregoing examples when taken together demonstrate that saidinvention has provided an in-mold decorating system that offers aplurality of capabilities not present in the prior state of the art.Said system implements in-mold decorating with a single layer sheet ofmaterial printed and coated using standard printing and coatingtechniques and moldable in molds heretofore not used for in-molddecorated parts, said molds needing no modification. The system providedby said methods described herein has allowed in-mold decorating to beapplied in thermoset applications where no process or system waspreviously available. The system provided by the methods describedherein has provided the capability to use electrostatic treatment tohold in-mold decorations in place in the most demanding environments.The system provided by said methods described herein has provided thecapability of adding in-mold graphic decoration without changes to moldsor equipment. The system provided herein has provided the capability toattach layers of material to products where previously said layers couldnot be made to adhere to the material from which the products weremanufactured.

What is claimed is:
 1. A method of in-mold decorating an article comprising the steps of: introducing a single layer sheet containing a printed and over-coated image into a mold, contacting said single layer sheet with a thermoplastic polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an in-mold decorated article.
 2. The method of claim 1 where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing and color or monochrome electrostatic laser printing.
 3. The method of claim 1 where said single layer sheet is a precipitated silica filled microporous material.
 4. The method of claim 1 where said over-coated image is accomplished using a method selected from the group consisting of lithography, screen printing, and roll coating.
 5. The method of claim 1 where said thermoplastic polymer is selected from the group consisting of polyolefins, polyesters, polycarbonate, elastomers, polyamides, polystyrene, polyphenylene oxide, polyvinyl chloride, partially devulcanized crumb rubber, crumb rubber filled polymer, and acrylonitrile-butadiene-styrene.
 6. The method of claim 1 where said mold utilizes a process selected from the group consisting of injection, blow, thermoforming, gas assist, or rotational molding.
 7. A method of decorating an extruded article comprising the steps of: providing a single layer sheet containing a printed and over-coated image, and permanently fusing said single layer sheet into the surface of a thermoplastic polymer during an extrusion process.
 8. The method of claim 7 where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing, and color or monochrome electrostatic laser printing.
 9. The method of claim 7 where said single layer sheet is a precipitated silica filled microporous material.
 10. The method of claim 7 where said over-coating is accomplished using a method selected from the group consisting of lithography, screen printing, and roll coating.
 11. The method of claim 7 where said thermoplastic polymer is selected from the group consisting of an of polyolefins, polyesters, polycarbonate, elastomers, polyamides, polystyrene, polyphenylene oxide, polyvinyl chloride, partially devulcanized crumb rubber, crumb rubber filled polymer, and acrylonitrile-butadiene-styrene.
 12. A method of decorating the top and side surfaces of a three dimensional molded product comprising the steps of: introducing a three dimensional graphically printed sheet into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce a fully decorated three dimensional article.
 13. The method of claim 12 where said graphic image is made three dimensional by a method selected form the group consisting of by heat welding, vacuum forming, ultrasonic welding, and coining.
 14. A method of in-mold decorating an article containing a raised area or areas intended for subsequent decoration using post molding decorating methods comprising the steps of: introducing a printed and overcoated sheet into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an article having a raised area within the graphic decorated area.
 15. The method of claim 14 where said subsequent post mold decorating method is selected from the group consisting of pad printing, heat transfer, foil transfer, screen printing, airbrush, and application of an adhesive label.
 16. A method of in-mold decorating an article comprising the steps of: introducing a single layer sheet containing a printed and over-coated image into a mold, contacting said sheet with a thermosetting or vulcanizable material, and permanently fusing said sheet into the surface of said material during a thermosetting or vulcanization molding process to produce an in-mold decorated article.
 17. The method of claim 16 where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing, and color or monochrome electrostatic laser printing.
 18. The method of claim 16 where said single layer sheet is a precipitated silica filled microporous material.
 19. The method of claim 16 where said over-coating is accomplished using a method selected from the group consisting of lithography, screen printing, application of curable silicone, and roll coating.
 20. The method of claim 16 where said thermosetting material is selected from the group containing thermosetting plastic and unvulcanized rubber.
 21. A method of decorating an extruded article during its manufacture comprising the steps of: placing a single layer sheet containing a printed and over-coated image into the surface of a material selected from the group consisting of thermosetting materials and vulcanizable materials and permanently fusing said single layer sheet to said material.
 22. The method of claim 21 where said single layer sheet is printed using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing, and color or monochrome electrostatic laser printing.
 23. The method of claim 21 said single layer sheet is a precipitated silica filled microporous material.
 24. The method of claim 21 where said over-coating is accomplished using a method selected from the group consisting of lithography, screen printing, and roll coating.
 25. The method of claim 21 where said thermosetting material is selected from the group containing thermosetting plastic unvulcanized rubber.
 26. A method of in-mold decorating an article molded from a transparent polymer with a different image on the opposing surfaces of a single layer sheet comprising the steps of: introducing a single layer sheet printed and overcoated on one surface and printed on the opposing side into a mold, contacting said sheet with a transparent polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an in-mold decorated article having one image on its top surface and a different image visible through said transparent polymer on its bottom surface.
 27. A method of treating via overcoating the surface of single layer sheet containing a printed image such that said printed sheet remains dimensionally and positionally stable in a mold during a molding process comprising the steps of: selecting a UV curable clear coating material having a coefficient of friction greater than 0.5 and a cured gloss of greater than 55%, transferring said coating to a sheet intended for in-mold decorating using a process selected from the group consisting of screen printing and roll coating, and curing said coating by exposure to UV energy to produce a cross linked coating.
 28. The method of claim 27 where said molding process is selected from the group consisting of injection molding, blow molding, rotational molding, gas assist molding, structural foam molding, extrusion and compression molding.
 29. The method of claim 27 where the mechanism for producing said positional stability is selected from the group consisting of imparting dielectric properties that permit positionally stable placement using electrostatic charging of said sheet in any position within a mold for over 30 seconds including during the molding process, imparting a coefficient of friction between said sheet and mold surface sufficient to resist the force of molding material flowing over the molding side of said sheet, imparting a surface that softens sufficiently to produce adhesion to said mold surface sufficient to resist the force of molding material flowing over the molding side of said sheet.
 30. The method of claim 27 where part design demands that the decoration be placed over the gate through which the molding material enters the mold.
 31. A method of treating via overcoating the surface of single layer sheet containing a printed image such that an article containing said printed sheet fused into its surface during manufacture exhibits enhanced properties selected from the group containing outdoor resistance to UV induced image fading for five to ten years, resistance to image degradation from contact with petroleum based materials or solvents, and resistance to underfoot slippage of greater than a 0.6 coefficient of friction as tested under ASTM D2047 comprising of the steps of: selecting a UV curable clear coating formulated with photochromic dies, solvent resistant acylate esters, and branched polymer chains, transferring said coating to a sheet intended for in-molding using a process selected from the group consisting of screen printing and roll coating, and curing said coating by exposure to UV energy to produce a cross linked coating having the required properties.
 32. A method of treating via sheet scoring comprising the steps of: printing an image on a single layer sheet, contacting said sheet with a steel roll die fabricated to impart a scored interlocking pattern, coating said sheet with a flexible coating having a tensile elongation of at least 150%, and die cutting said sheet to produce a label for in-molding on a flexible material where said image can flex and recover to original dimensions without permanent image distortion.
 33. A method of decorating an article made using recycled or regrind materials comprising the steps of: introducing a printed and overcoated single layer sheet into a mold, contacting said sheet with a material containing non-homogeneous and varigated material derived from recycled or regrind feedstocks, and permanently fusing said sheet into the surface of said material during the molding process to produce an in-mold decorated article where the unacceptable appearance non-homogeneous and varigated visible surface of said article is hidden from view by said graphic image.
 34. A method of permanently attaching a label comprising the steps of: introducing a single layer sheet containing a printed and overcoated image into a mold, contacting said single layer sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an article where the intended use makes it essential that said label remain attached and readable.
 35. The method of claim 34 where said label has an intended use selected from the group consisting of serialized tracking, conveying safety information, providing product support or warranty information, and identification using a barcode.
 36. A method of in-mold decorating a molded article without modifying the mold used in said molding process comprising the steps of: introducing a single layer sheet containing a printed and over-coated image into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during the molding process to produce an in-mold decorated article.
 37. A method of transferring labels for in-mold decorating comprising the steps of: placing single layer labels containing a printed and over-coated image into a spring loaded cassette image side down, removing said labels from said cassette one at a time using a vacuum actuated robotic end of arm tool, transferring said label to a mold cavity using a robot and end of arm tool, and pinning said label to the mold using an electrostatic device attached to said end of arm tool.
 38. A method of using a silica filled microporous material to create a surface for attachment of sheet material where adhesives are incapable of effecting a permanent attachment to the underlying materials comprising the steps of: introducing a silica filled microporous sheet into a mold, contacting said sheet with a polymer, and permanently fusing said sheet into the surface of said polymer during to molding process to produce a molded surface capable of accepting adhesives for attachment of other materials to the molded surface.
 39. The method of claim 38 where said sheet material is selected from the group consisting of films containing a pressure sensitive adhesive, adhesive reflective laminates, metallized foils, and laser etched reflective or refractive foils.
 40. The method of claim 38 where method of attachment of said sheet material is selected from the group consisting of first attaching to said microporous material followed by fusing to said underlying material, first fusing to said underlying material followed by attachment of sheet material to said microporous material and fusing to said underlying material with the intent of future attachment of said sheet material.
 41. A method of using a silica filled microporous material to create on a first material a surface for attachment of a second dissimilar material without adhesives where said first and second materials could not normally be caused to fuse to one another comprising the steps of: introducing a silica filled microporous sheet material into a mold, contacting said sheet material with a polymer and permanently fusing said sheet material into the surface of said polymer during the molding process to produce a surface to which a second and dissimilar polymer can be fused creating a bond between dissimilar polymers.
 42. The method of claim 41 where said first and second materials are selected from the groups consisting of rubber and plastic, polyolefin plastic and acrylonitrile-butadiene-styrene.
 43. The method of claim 41 where said materials are used to make a shoe sole.
 44. A method of creating an article containing electrically conductive areas comprising of the steps of: applying an electrically conductive film material to one surface of a microporous sheet, introducing said sheet into a mold or an extrusion process, contacting said sheet with a polymer and permanently fusing said sheet into the surface of said polymer to produce an article having conductive areas.
 45. The method of claim 44 where said conductive area forms a product usable in an application selected from the group consisting of electrical circuits and electromagnetic shields.
 46. An article produced by the method of claim
 1. 47. The article of claim 47 where said article is selected from the group consisting of a table top, a chair, a control panel, a logo label, a molded toy, a fishing lure, a molded carrying case, a lampshade, a trash container, a tool housing, a vacuum cleaner, a case for a compact disk or DVD, mailbox, a child safety seat, toilet seat, an enclosure for a dart board, a container for cosmetics, a barrel for transporting or storing chemicals, a plate intended to hold food, a cup or tumbler intended to hold a beverage, the door of a safety deposit box, a water-fowl decoy, a chute on a lawn mower, a three dimensional lid for a beverage cooler, an escutcheon panel for an appliance, a cover plate for a wall mounted electrical switch or outlet, and the opaque surround area of a clear plastic projection lens.
 48. The article of claim 47 where said image is created using a method selected from the group consisting of lithography, screen printing, flexography, high resolution ink-jet printing, and color or monochrome electrostatic laser printing.
 49. The article of claim 47 where said thermoplastic material is recycled plastic.
 50. An article produced by the method of claim
 16. 51. The article of claim 50 where said molding process is selected from the group consisting of injection molding, vulcanization and compression molding.
 52. The article of claim 50 where said article is selected from the group consisting of tires, belts, housings and enclosures.
 53. The article of claim 50 where said printed image is selected from the group consisting of barcodes, logos, text, numbers, and metallic appearance graphics.
 54. The article of claim 50 where said coating prevents damage to said image from exposure to petroleum distillate materials.
 55. The article of claim 50 where said article is selected from the group consisting of truck mud flaps, signs, and underfoot advertising mats.
 56. The article of claim 50 where said article exhibits a coefficient of friction greater than 0.60 as measured under ASTM
 2047. 57. The article of claim 50 where said vulcanizable material is derived from over 50% recycled tires.
 58. An article created by the steps of applying a metallic material to the surface of a silica filled microporous polymer sheet, introducing said sheet into a mold or extrusion device, contacting said sheet with a polymer and permanently fusing said sheet into the surface during a thermoplastic or thermoset molding process.
 59. The article of claim 58 where said article is selected from the group consisting of reflective element of a light assembly, a mirror in a cosmetic container, and electrical circuit, and an electromagnetic shield.
 60. An article produced by the method of claim
 41. 61. The article of claim 60 where said first and second substrate materials are selected from the group consisting of a polyolefin plastic with acrylonitrile-butadiene-styrene and rubber with plastic.
 62. An article produced by the method of claim
 38. 63. The article of claim 62 where said reflective laminate is adhesively attached to said molded surface. 